1. Purpose
Standardize the inspection process of finished products, provide the basis for judgment, ensure that the product quality can meet the customer requirements, prevent unqualified products from leaving the factory, avoid unnecessary economic losses, improve work efficiency, and customer satisfaction.
2. Scope of Application
Suitable for product inspection.
3. Sampling Criteria
3.1 Dimensional Tolerances and Magnetic Properties "Sampling Standard."
3.2 Appearance: This process involves sampling inspection, with the packaging section responsible for full inspection.
3.3 The acceptance criterion for automotive products is zero defects.
4. Test Conditions
The fluorescent lamp should be within 1 meter of the desk.
5. Work Regulations
5.1 The finished product inspection team is responsible for the implementation, recording, and feedback of the inspection work.
5.2 Reasonable inspection methods shall be determined for all products, and inspection shall be carried out only after confirmation.
5.3 Special inspection methods shall be used for products with special specifications.
5.4 The workbench should be kept clean and tidy. Materials with similar specifications should not be tested on the same workbench at the same time to prevent mixing.
5.5 The inspection process should be handled gently to avoid scratches on the surface coating or corners missing due to mutual collision.
6. Essential Measuring Tools for Inspection, and Their Usage and Maintenance Requirements
6.1 Essential measuring tools for product inspection: various Vernier calipers, micrometers, dial indicators, right-angle rulers, V-blocks, universal angle gauges, feelers, radiometers, projectors, and other custom-made auxiliary measuring tools.
6.2 Before inspection, check whether the measuring instrument is in good condition and do a good job of calibration.
6.3 When abnormal size tolerance is found in the inspection process, the measuring instrument used shall be recalibrated and confirmed.
6.4 During the measurement process, the measuring head of the measuring instrument should be flat with the product surface to avoid affecting the deviation of the reading.
6.5 When measuring tools are not used, they should be in the state of zero and put in the designated position. If they are not used for more than 2 days, they should be coated with special anti-rust oil to prevent corrosion.
6.6 Measuring tools should be handled gently to avoid vibration-induced measurement deviations.
6.7 If there is a deviation in the quantity, report for repair in time to avoid misuse and affect product quality.
7. Inspection Process
7.1 Verify product consistency between physical items, labels, delivery notes, and order records (before inspection, carefully compare physical items with label cards and order details regarding model No.s, specifications, coating types, and quantities to prevent material confusion).
7.2 Verify incoming material quantities.
7.3 Confirm product orientation.
7.4 Measure dimensions in all directions using a vernier caliper (sample 2-5 pieces).
7.5 Randomly inspect dimensional tolerances, including parallelism, perpendicularity, roundness, and Concentricity.
7.6 Conduct surface quality checks (surface finish, chamfering, coating quality, etc.).
7.7 Maintain inspection records.
7.8 Fill out the "Product Transfer-in Inventory Form".
7.9 Display qualified labels (for products requiring coating tests, salt spray tests, PCT, drop tests, etc., initially place "Test" labels; replace with "Qualified" labels upon passing tests).
7.10 Perform a full surface inspection in the packaging section.
7.11 Conduct performance testing and process inspections.
7.12 Verify product quality and packaging requirements after packaging.
7.13 Confirm non-conforming products.
7.14 Verify total quantity.
7.15 Promptly arrange rework or repair of defective products.
8. Color Classification
White Bag: Product to Be Inspected
Red Bag: Demagnetized Products
Yellow Bag: Retouched Products
Blue Bag: Complementary Product
White Box: Waste Material
Red Box: Processed Waste
Yellow Box: Reprocessing or Utilization
Blue Box: Complementary Products
9. Inspection Methods and Standards
For products requiring testing, arrange or notify relevant tests (such as coating tests, salt spray tests, PCT tests, aging tests, HAST tests, wetting tests, etc.) within 2 hours after receiving the products. If the products have special requirements, special specifications shall be followed.
9.1 Orientation Inspection Methods and Standards
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Item |
Tools |
Standard |
Method of Calibration |
Photo |
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Orientation |
Magnetic Rod: Demagnetization coil |
Meets order or drawing Requirements: The radial groove or irregular shape should be observed with a magnetic flux line observation sheet after magnetization to check whether the magnetic flux line direction is consistent with the drawing. |
The orientation direction is determined by the magnetic force direction of the magnet rod. For large square products, orientation identification requires using an iron plate: the direction where the product adheres firmly to the plate indicates the orientation. Note that the magnet rod must not be contaminated with magnetic powder or metal particles. The iron plate should be wrapped in plastic bags or tape to prevent surface coating scratches. For unmagnetized products or those requiring electroplating rework, orientation can be identified through demagnetization coils – the heaviest feel corresponds to the correct orientation. When the orientation direction size of the raw material is different from the size of any other direction within 2.5mm, the orientation error phenomenon is easy to occur during processing. Therefore, the finished product must be fully inspected for orientation. The black sheet inspection flow that is not fully inspected must be fully inspected for orientation by the finished product. Note: After product orientation confirmation, the surface magnetic force must be ≤100GS due to magnetic rod attraction. |
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General small product-oriented test |
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Big square orientation test |
9.2 Inspection Methods and Standards for Dimensional and Form, and Position Tolerances
9.2.1 Inspect strictly according to the requirements of the order and drawings. For products with attached drawings, carefully review the requirements on the drawings to avoid missing inspection.
9.2.2 When measuring dimensional tolerances, high-precision micrometers should be used. If micrometers are unavailable, Vernier calipers with digital displays or digital Vernier calipers should be employed (when measuring internal holes, ensure the calipers are properly calibrated before use).
9.2.3 For each dimensional tolerance, record 20 original parameters, documenting both maximum and minimum values for any deviations; for form and position tolerances, record only the maximum value.
9.2.4 Control requirements for various dimensional tolerances and form and position tolerances. (Before product inspection, verify that the order and drawings are consistent. If discrepancies are found, provide feedback and confirmation promptly.)
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Inspecting Item |
Testing Equipment |
Acceptance Standard |
Exception Handling |
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Size Common Difference |
Micro calliper or vernier callipers Ensure gauge accuracy |
Order and drawing requirements. |
Report any anomalies immediately and rework as necessary. For items that can be released, maintain proper release records and verify whether they require separate processing. |
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Bevel Size C or R |
Vernier calipers radius gauge |
Order requirements. |
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Verticality ⊥ |
Universal protractor or square, jigsaw, or custom dial indicator |
Order or drawing requirements, No special requirements: "Form and Position Tolerance Standard". |
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Depth of Parallelism ∥ |
Microcalliper |
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Concentricity ◎ |
Vernier calipers or a custom dial indicator |
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Roundness ○ |
Custom V-shaped groove and a percentage chart |
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Flatness
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Flat plate, straight edge ruler, feeler gauge |
9.2.5 Verticality Inspection Diagram:
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Shape |
Illustration |
Measure Accuracy |
Diagrammatic Sketch |
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Circles and Rings |
Roll the product on the flat surface (preferably from a sloping surface) to check if the product swings significantly from side to side. (If the product is too thin to see the swing, do not press this button.) |
The rough measurement method is used for products where the customer does not have special requirements for Verticality. |
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Square, Arc-shaped |
Align products in the same direction and use a straightedge to check for neat front-to-back alignment and absence of uneven protrusions or indentations. (For elongated products) |
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Square, Arc-shaped |
Align products in the same direction with flat surfaces. Use a straightedge to check for gaps between products and on both sides. (For long products) |
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Any specification |
Hold the product with your left hand against the measuring surface and rotate the rear handle with your right hand until the product is in close contact with the measuring surface. |
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Any Specification |
Press the square against the product and check for gaps between the flat surface and the square. Then measure the gap with a feeler gauge. |
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Any Specification |
The product is tightly attached to the 90-degree side. Use the dial gauge measuring head to measure the four diagonal points at the top edge of the product, and check the dial gauge swing deviation value measured by the four points. The square moves up and down, measuring the swing deviation of the dial gauge at the top and bottom. |
The precise measurement method is used for products where the customer has vertical requirements. |
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9.2.6 Measurement of dimensional, form, and position tolerances for products of various shapes
When inspecting related accessories for products, strictly follow the order requirements. (For products with multiple pieces assembled with gaps, inspect approximately 5% of the samples; for products with positioning holes, inspect approximately 10% of the samples; for products requiring individual inspection, such as bushing rods and bushed selenium steel sheets, conduct full inspection before shipment).
9.2.6.1 Cylinder/Sphere Inspection
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Inspecting Item |
Inspection Tool |
Test Methods and Requirements |
Photo |
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External diameter D or Φ |
Outside micrometer or vernier calipers |
Measure the outer circle at both ends and the middle with a micrometer at least three points. (Measure one point for sheet products) Just use the vernier caliper to measure the outer diameter. |
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Height or Thickness H or T or L |
Outside micrometer or vernier calipers |
Measure at least three points on the edge and in the middle. |
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Roundness ○ |
Custom V-groove and dial gauge |
Place the product into the homemade V-shaped groove, measure with a dial gauge, rotate the product, and read the deviation value of the pointer swing. |
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Verticality ⊥ |
universal protractor or square, jigsaw, or custom dial indicator |
Hold the product with your left hand against the measuring surface and rotate the rear handle with your right hand until the product is in close contact with the measuring surface. See 9.2.5 for the selection of appropriate testing methods when required by the customer. |
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Depth of parallelism ∥ |
Outside micrometer |
Measure multiple points in a plane with at least four points, and take the difference between the maximum and minimum values. |
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9.2.6.1 Cylinder/Sphere Inspection
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Inspecting Item |
Inspection Tool |
Test Methods and Requirements |
Photo |
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External Diameter D or Φ |
Outside micrometer or vernier calipers |
Measure the outer circle at both ends and the middle with a micrometer at least three points. (Measure one point for sheet products) Just use the vernier caliper to measure the outer diameter. |
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Height or Thickness H or T or L |
Outside micrometer or vernier calipers |
Measure at least three points on the edge and in the middle. |
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Roundness ○ |
Custom V-groove and dial gauge |
Place the product into the homemade V-shaped groove, measure with a dial gauge, rotate the product, and read the deviation value of the pointer swing. |
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Verticality ⊥ |
Universal protractor or square, jigsaw, or custom dial indicator |
Hold the product with your left hand against the measuring surface and rotate the rear handle with your right hand until the product is in close contact with the measuring surface. See 9.2.5 for the selection of appropriate testing methods when required by the customer. |
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Depth of parallelism ∥ |
Outside micrometer |
Measure multiple points in a plane with at least four points, and take the difference between the maximum and minimum values. |
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9.2.6.2 Ring Inspection
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Inspecting Item |
Inspection Tool |
Test Methods and Requirements |
Photo |
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External Diameter D or Φ |
Outside micrometer or vernier calipers |
Measure the outer circle at both ends and the middle with a micrometer at least three points. (Measure one point for sheet products) Just use the vernier caliper to measure the outer diameter. |
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Bore Size D or Φ |
Outside micrometer or vernier calipers |
The measuring head should be attached to the inner circle of the product and measure more than three points. |
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Altitude H or T or L |
Outside micrometer or vernier calipers |
Measure at least three points on the edge and in the middle. |
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Concentricity ◎ |
Vernier calipers |
Measure at multiple points along the pipe wall and calculate the difference between the maximum and minimum values. The fixture can also be made to measure with a dial gauge. |
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Verticality ⊥ |
Universal protractor or square, jigsaw, or custom dial indicator |
Hold the product with your left hand against the measuring surface and rotate the rear handle with your right hand until the product is in close contact with the measuring surface. See 9.2.5 for the selection of appropriate testing methods when required by the customer. |
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Depth of Parallelism ∥ |
Outside micrometer |
Measure multiple points in a plane with at least four points, and take the difference between the maximum and minimum values. |
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Roundness ○ |
Homemade V-groove and dial indicator |
Place the product in a self-made V-groove, measure with a dial indicator, rotate the product, and read the deviation value of the pointer swing. |
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9.2.6.3 Square Test
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Inspecting Item |
Inspection Tool |
Test Methods and Requirements |
Photo |
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Length L Width W Height H/T |
Outside micrometer or vernier calipers |
Measure at least five points at each corner and in the middle. |
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Verticality ⊥ |
Universal protractor or square, jigsaw, or custom dial indicator |
Hold the product with your left hand against the measuring surface and rotate the rear handle with your right hand until the product is in close contact with the measuring surface. See 9.2.5 for the selection of appropriate testing methods when required by the customer. |
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Depth of Parallelism ∥ |
Outside micrometer |
Measure at least five points at each corner and in the middle, and take the difference between the maximum and minimum values. |
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9.2.6.4 Inspection of Non-standard Shapes (Including Wavy Profiles) (Products requiring tool grinding or special cases where self-stop gauges must be used for measurement)
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Inspecting Item |
Inspection Tool |
Test Methods and Requirements |
Photo | |
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Width/Top/Bottom Span W/a |
Universal protractor Vernier calipers |
For the span values and angles, if the span is an angle and the span dimension is not specified, convert it to a span dimension value. |
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Wall Thickness T |
Wall thickness micrometer gauge or Vernier calipers |
Measure the wall thickness at multiple points at the beginning, end, and middle. |
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Altitude H |
Outside micrometer or Vernier calipers |
Measure at each corner and multiple points in the middle, with at least 3 points. |
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Verticality ⊥ |
Universal protractor or Square, jigsaw, or Custom dial indicator |
Hold the product with your left hand against the measuring surface and rotate the rear handle with your right hand until the product is in close contact with the measuring surface. See 9.2.5 for the selection of appropriate testing methods when required by the customer. |
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Depth of parallelism ∥ |
Outside micrometer |
Measure at least five points at each corner and in the middle, and take the difference between the maximum and minimum values. |
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Concentricity ◎ |
Visual or self-stop gauge |
The wall thickness is visually consistent with the drawing requirements, with a uniform size and no deviation. |
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9.2.6.5 Inspection of Grooved Products
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Inspecting Item |
Inspection Tool |
Test Methods and Requirements |
Photo |
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Groove Width |
Order or drawing requirements |
The width of the slot should be uniform. |
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Groove Depth |
Order or drawing requirements |
Generally, the groove Depth should not be too shallow (i.e., the size should not be too small). The specific requirements should follow the order of drawings. |
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Slot Position |
Order or drawing requirements |
Measure the gap between the slot and the product edge on both sides and read the difference. |
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9.2.6.6 Inspection of Products with Small Holes, Such As Discs and Rings
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Inspecting Item |
Inspection Tool |
Test Methods and Requirements |
Photo |
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Small Hole Position Tolerance |
Order or drawing requirements Unspecified items follow the Geometric Tolerances Standard |
Measure the distance between holes. |
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Measure the distance between the hole wall and the left and right edges of the product. |
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9.2.6.7 Inspection of Products With Small Holes, Such As Square and Tile Shapes
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Inspecting Item |
Inspection Tool |
Test Methods and Requirements |
Photo |
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Small Hole Position Tolerance
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Order or drawing requirements Unspecified items follow the "Form and Position Tolerance Standard."
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Measure the distance between holes. |
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Measure the distance between the hole and the transverse and longitudinal edges of the product. |
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9.2.6.8 Self-Positioning Hole Inspection for Small Hole Products
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Inspecting Item |
Inspection Tool |
Acceptance Standard |
Test Methods and Requirements |
Photo |
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Angle of Chamfer Size |
Vernier calipers |
Order or drawing requirements |
Measure each chamfer edge (right angle) |
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Radius gauge |
Order or drawing requirements |
Measure each chamfer edge (round edge) |
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9.3 Appearance Inspection Methods and Inspection Standards
The surface of the product is bad, and the products with rework allowance should be reworked (except those allowed to be released), and the appearance quality of the products should be guaranteed as far as possible.
If defective products can be used, keep a release record.
9.3.1 Appearance inspection method
9.3.1.1 Visual inspection of product appearance.
9.3.1.2 The small products are placed on the cardboard and spread out for inspection. After checking one side, the cardboard is pressed down, and the other side is checked.
9.3.1.3 The side shall be checked by hand row by row, and the magnetic chain suction test may be used when necessary.
9.3.1.4 For products with deep holes or rings, visually inspect with light under hand-held observation; shallow holes can be visually inspected on cardboard.
9.3.2 General principle of appearance judgment: The surface shall not have obvious cracks, sand holes, spots, scratches, knife wires, coating bubbles, electroplating water stains, electroplating yellowing, coating peeling, or other undesirable phenomena. The surface can be wiped and ignored.
9.3.3 The product surface shall be clean and free from any stubborn stains that cannot be wiped off.
9.3.4 Appearance Inspection Standards for Products of Different Shapes:
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Shape Classification |
Visual Inspection Criteria |
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Circle/Square |
1. Pay attention to the outer diameter and narrow face to see whether there is a defect, such as a missing corner. |
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Ring |
1. Pay attention to whether there is a crack or a corner burst phenomenon on the edge of the hole. 2. Pay attention to whether there is a defect, such as a missing corner, on the outer diameter. 3. There is no obvious position deviation in the visual inspection of the Concentricity. |
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Standard Wave |
1. If it is a wire-cutting product, the surface molybdenum wire should be uniform and without blackening. 2. The wall thickness is concentric, with no deviation, and no burrs protruding on both sides of the outer R. |
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Hole Product |
1. Pay attention to whether there is a crack or a corner burst phenomenon on the edge of the hole. 2. Whether the position of the hole meets the drawing requirements. 3. Is there any deviation in the hole distance? 4. Whether the Depth of the deep hole meets the drawing requirements. |
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Notched Product |
1. Whether the position of the groove meets the drawing requirements. 2. Whether there is rust and a blackening phenomenon in the coating of the groove. 3. Check whether the Depth and width of the groove are abnormal. |
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Other Alien |
1. Check the appearance compliance strictly according to the drawings. |
9.3.5 Coating Inspection Standard: (The coating color between batches of products in the same order should be similar, especially for galvanized products)
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Seed |
Coating inspection standard |
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Copper Nickel Nickel |
The surface color is uniform, without rust spots, yellow stains, water stains, and other bad marks; no bubbles, cracks, pores, burrs, or other visible defects of the coating. |
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Black Nickel |
The surface color is uniform and black, without rust spots, yellow marks, water marks, or other bad marks. |
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Blue and White Zinc |
The coating should be uniformly blue and white, with slight interference color patterns allowed. It must be free from rust spots, yellow stains, water stains, zinc loss, or other defects. Visible defects such as bubbles, cracks, pores, or burrs are not permitted. |
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Color Zinc |
The surface should be clear and bright with a rainbow color, and no adhesion or white leakage is allowed. No visible coating defects such as bubbles, cracks, pores, burrs, etc. |
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Black Zinc |
The surface shall be black with no visible scratches or white leakage. No visible coating defects such as bubbles, cracks, pores, or burrs shall be present. |
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Nickel-Cased Tin |
The coating shall be uniform in color, free from yellowish-white spots and tin crystal patterns, and shall be free from visible defects such as bubbles, cracks, pores, and burrs. |
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Nickel-Plated Gold |
The coating shall be bright golden yellow with uniform color and no visible defects such as fogging, whitening, blistering, cracking, porosity, or burr. |
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Nickel-Plated Silver |
White, slightly blue, without yellow discoloration, water marks, bubbles, cracks, pores, burrs, and other visible coating defects. |
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Nickel-Cased Chromium |
Bright silver-white, uniform color, no yellow discoloration, water marks, bubbles, cracks, pores, burrs, and other visible coating defects. |
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Phosphorization |
No yellowing, ash hanging, or obvious thick crystals. |
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Electrophoretic Paint |
The film is full and glossy, and no shrinkage holes, orange peel, flow marks, hanging drops, or obvious hanging marks are allowed. |
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Teflon |
The film is full and glossy, and no shrinkage, orange peel, flow marks, or hanging drops are allowed. |
9.3.6 Common Types of Appearance Defects and Inspection Standards
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Unhealthy Phenomenon |
Acceptance Standard |
Photo |
Exception Handling |
Remarks |
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Impurity Blowhole |
The surface must be free of impurities and pores |
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Release or scrap |
Material cause |
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Pit |
There should be no sand hole or depression larger than D0.5mm on the surface |
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Release or scrap |
Material cause |
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Internal Crack |
No surface cracking |
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Announce an invalidated check in paper |
Punching or material issues |
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Announce an invalidated check in paper |
Material cause |
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Electrical Circuit |
No magnetic circuit phenomenon on the surface |
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Demagnetization and re-plating or serious scrap (Nickel plating or epoxy products are first removed, then demagnetized, and finally electroplated) |
The surface magnetic force is too high before electroplating |
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Polish Scratches |
There should be no obvious "fish phosphorus" pattern on the surface |
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Release, rework, or scrap (Nickel plating or epoxy products are first removed, then ground, and finally electroplated) |
The grinder is too hard, the speed is too fast, and the sandpaper is too sharp |
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The surface should not have obvious sandpaper silk printing |
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The sandpaper is too coarse, or the grinding technique is not correct, or the force is not correct |
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Grinding Wheel Wire |
The surface should not have an obvious grinding wheel wire |
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Release, rework, or scrap (Nickel plating or epoxy products are first removed, then ground, and finally electroplated) |
Reasons for large grinding or double-sided slicing grinding |
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Crystallization Defect |
The disadvantage of crystallization is that 30% of the surface area is lost |
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Let sb. pass |
Material cause |
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Unfilled Corner |
The surface must not have any corner defects larger than D1. Products exceeding D1 specifications may be approved for D2 standards, with one defect allowed per surface and two per product |
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Release or supplement the angle to rework or scrap (Nickel plating or epoxy products are first removed, then the corners are filled, and finally electroplated for rework) |
The cooking temperature is too high, or the temperature difference is too large, resulting in an oxide deficiency |
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The slice has missing edges or corners, or the slice is not cut properly |
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Improper processing or circulation protection |
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Edge Cracks |
Small-sized roll-coated products must not exhibit edge chipping or cracking; large-sized hanging-coated products may have minor cracks up to |
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Release, rework, or scrap (Nickel-plated or epoxy products are first removed, then the edge is removed to compensate for the corner, and finally, electroplated for rework) |
The billet may collide during processing or flow |
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Ripple |
The inner hole must not have a chamfer |
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Announce an invalidated check in paper |
The reason for the hole punching may be oxidation |
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Cutting Blade |
The surface cannot have a tactile feel |
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Release, rework, or scrap (Nickel plating or epoxy products are first removed, then ground, and finally electroplated) |
Slicing processing reason |
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Molybdenum Filament |
No obvious molybdenum wire should be present on the surface |
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Release or rework (Nickel plating or epoxy products are first removed and then ground back, and finally electroplated back) |
Wire cutting processing reasons |
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Edge Smoothing |
The wire-cut tile surface must be free of protruding burrs, primarily on the outer arc. |
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do poorly done work over again (Nickel plating or epoxy products are first removed, then ground, and finally electroplated) |
Wire cutting processing reasons |
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Lan |
There should be no pinhole-type decay on the surface |
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Release, rework, or scrap (Nickel plating or epoxy products are first removed and then ground back, and finally electroplated back) |
Improper processing or transfer of protection |
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Orange Peel |
There should be no obvious orange peel phenomenon on the surface |
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Release, re-plating, or scrap |
Electroplating cause |
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The Oxygenation Point Is too High |
The surface of epoxy products should not have more than 2mm hanging points |
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Generally, oil-based markers are used to repair the hanging points, and severe cases require re-plating treatment. |
Electroplating cause |
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Bubbling or Edge Lifting Occurs on The Edge Coating |
The edge coating should not have bubbles or edge lifting |
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Increase chamfer (if the order does not require chamfer size); generally re-plating; in severe cases, scrap (Nickel plating or epoxy products are first removed, then chamfered, and finally electroplated) |
Electroplating may be caused by a small chamfer of the inner hole |
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Poor Complementary Angle (blackened, Blistered, Pinhole) |
The complementary angle should not show blackening, blistering, or pinhole effects. |
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Release, rework, or scrap (Nickel plating or epoxy products are first removed, then the corners are filled, and finally electroplated for rework) |
Reason for the complementary angle or plating |
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Poor Complementary Angle |
No protrusions or depressions should be present in the complementary area |
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Redo or scrap (Nickel plating or epoxy products are first removed, then the corners are filled, and finally electroplated for rework) |
Reason for the supplementary angle |
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Poor Complementary Angle |
There should be no bulge in the corner of the epoxy product |
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Redo or scrap (Nickel plating or epoxy products are first removed, then the corners are filled, and finally, electroplated) |
Electroplating or supplementary angle |
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Coating Peeling |
The electroplating layer and the matrix should not be separated |
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Replating or scrap |
Poor substrate or plating |
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Electroplating Foaming |
No bubbling should occur on the electroplated surface |
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Replating or scrap |
Electroplating cause |
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Electroplating Bubble |
No bubble phenomenon should be present on the electroplated surface |
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Redo or scrap |
Electroplating causes or impacts after plating |
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Electroplating Overlay |
The electroplated surface must not have a tactile overlay |
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Release or scrap |
Electroplating cause |
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Coating Peeling and Edge Lifting |
The coating surface should not be detached or curled |
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Release or scrap |
Electroplating cause |
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Macula Watermark |
The electroplated surface should not have yellow spots or water marks |
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Replating (Nickel-plated products can be wiped directly with dilute sulfuric acid, and galvanized products can be re-plated) |
Electroplating cause |
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Electroplating Black |
The electroplated surface should not be blackened |
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Replating or scrap |
Electroplating cause |
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Fresh Cut Corners |
The electroplated surface must not have fresh corners |
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Replating or scrap |
Improper protection after electroplating |
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Electroplating Missing Corner |
The surface must not have any corner defects larger than D1. Products exceeding D1 specifications may be approved for D2 standards, with one defect allowed per surface and two per product. |
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Release or supplement the angle, rework, or scrap (Nickel plating or epoxy products are first removed, then the corner is filled, and finally electroplated) |
Electroplating cause |
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Scratch After Plating |
The surface should not have fresh scratches or an exposed zinc layer |
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Replating |
Reasons for electroplating flow protection |
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Electrolytic Corrosion |
No severe material ingress should occur on the surface |
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Release, rework, or scrap (Nickel plating or epoxy products are first removed and then ground back, and finally electroplated back) |
Electroplating cause |
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9.3.7 Inspection methods and standards for chamfer quality
Inspect according to the order or drawing requirements. Note that the chamfer size of each edge of the same batch of products must be uniform and consistent. There must be no wave-shaped vibration or leakage chamfer.
9.3.8 Inspection methods and standards for supplementary angles
9.3.8.1 Unless otherwise specified by the customer, all notches (or burrs and cracks) exceeding D2-D3 in size shall undergo chamfering treatment.
9.3.8.2 The joint between the corner and the base must be flat and smooth, with no gaps, pores, blackening, bubbling, or blistering.
9.3.9 Other appearance inspection requirements
9.3.9.1 For blackened tablets, no corner filling shall be performed unless otherwise specified.
9.3.9.2 For black tablets, if not shipped with magnetization, ensure surface quality and do not carry magnetism.
9.4 Performance Testing Methods and Inspection Criteria
9.4.1 All magnetized products shall undergo performance testing (the sampling ratio may be reduced appropriately for products with large specifications involving safety accidents).
9.4.2 For non-magnetized products, conduct performance testing using defective samples (including those with pores, impurities, surface defects, etc.). Products with significant angular defects or cracks shall not be sampled. For products without defects but with low coercivity, perform demagnetization on packaging coils to ensure complete demagnetization. Post-testing demagnetization must result in a surface magnetic force below 100Gs to avoid customer dissatisfaction.
9.4.3 Generally, the main test is magnetic flux, and only 5-10 pieces of surface magnet are required for reference. If the customer has specified test items or control requirements, the test shall be carried out according to the customer's requirements.
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Item |
Inspection Methods and Key Points |
Photo |
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Magnetic Flow |
Method of adjusting the size of the measuring tool: Square, tile-shaped, and other elongated shapes: half the length and width Circle: Radius Ensure the data drift amount remains stable Magnetic flux unit (Wb): 1 Wb equals 1000 mWb, where 1 T×m² equals 1 V×S |
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Magnetic Moment |
Magnetic moment M=Ф×C, C is the coil constant, in cm. Ф The magnetic flux value displayed by the flux meter. Br=Ф×C/V |
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Table |
In the absence of customer requirements, the maximum magnetic field test is generally performed (for large circular discs, the consistency of one full R/2 cycle must be tested) If the customer requests it, we will do so Magnetic field unit (T): 1T = 10,000Gs |
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Bore a Hole |
Observe the magnetized product with a magnetic flux line observation sheet |
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9.4.4 Test principles: The concave surface of the tile-shaped product is tested first; the product with an irregular shape is tested first on the side with a large contact area; the product with a sunken hole is tested first on the small hole surface; the multi-pole magnetized product is tested with waste to fill two poles to measure the magnetic flux.
9.4.5 Magnetic flux consistency standard: the maximum and minimum values are controlled within 10%.
9.4.6 Maximum magnetic consistency standard: The maximum and minimum values shall be controlled within 250Gs (if the customer does not require consistency, it can be released within 350Gs).
9.4.7 Magnetic moment consistency standard: the maximum and minimum value control range is within 5%.
9.4.8 Irregular shapes or tile shapes are compared with the measured data values on the same side.
10. Process Inspection and Factory Inspection Methods and Standards
10.1 After product inspection, process inspection, and factory inspection, the inspection should be strengthened for packaging operations.
10.2 The product bag must be free of water or moisture and should not exhibit any heating signs. For epoxy products, a minimum of 36 hours post-extraction from the oven is required before magnetization. Other plating products may be packaged and magnetized after 2 hours of cooling and drying. When vacuum packaging zinc-coated products, complete cooling must be ensured first to prevent discoloration of the zinc layer and detachment of the coating.
10.3 For composite coating and epoxy products, ensure no missed hanging points; use oil-based marker pens to fill them.
10.4 For nickel or chromium-coated products, any surface defects, such as water stains or yellowing, can be removed by wiping with diluted sulfuric acid. However, galvanized products must not be wiped, as this may damage the passive film and compromise corrosion resistance.
10.5 Main Items of Process Inspection and Factory Inspection:
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Order No. |
Inspection Item |
Inspection Methods and Standards |
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1 |
Product Essentials |
Confirm the brand, specification, orientation, chamfer, and coating of the packaged product. |
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2 |
Magnetic Requirements |
Is it magnetized? Is it multi-pole magnetized? 1. When packaging products that are not magnetized, it is not allowed to use magnetic rods to attract the packaging to prevent the products from being magnetized. 2. For magnetized products, except for standard shapes like pure circular rings, square blocks, and circular discs, all other products (especially irregular ones such as countersunk holes, tile-shaped, and trapezoidal shapes) must strictly follow the order and drawings. Clearly specify whether magnetization is applied in both directions or in one direction, along with the magnetic polarity direction of the N and S poles, to prevent pole reversal. |
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3 |
Polarity Marking Requirements |
For products with labeling requirements, the labeling method and color must comply with the order specifications. The labels should be aesthetically pleasing, neat, consistent, and fade-resistant. |
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4 |
Printing Requirements |
For printed materials, verify that the text on the stamp matches the client's specifications, ensuring no typographical errors or omissions. During printing, prevent the fixture from scratching the surface coating. The text must be clear and legible, avoiding faint or blurred characters. Only proceed with subsequent packaging after the text has fully dried. |
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5 |
Clips Washers |
Depending on the product's specifications, dimensions, orientation, and surface coating, select the appropriate clamp. Clamps or gaskets. When selecting clamps or gaskets, adequate consideration must be given to moisture resistance and protection against dampness absorption, as these components may rust and compromise surface coating quality. The surfaces of clamps or gaskets should not be excessively rough or have burrs. Wooden clamps require encapsulation treatment, and products with zinc plating or epoxy coatings should preferably use soft clamps to prevent surface scratches. For paper clamps, the adhesive side must have a glossy finish to prevent moisture absorption and subsequent rusting. The thickness of gaskets should ensure easy separation after magnetization, allowing customers to use them conveniently and safely. Generally, circular products larger than D13X2mm and square products exceeding 15X10X5mm require clamps or gaskets in packaging (custom specifications are subject to customer requirements, as detailed in the order). |
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6 |
Packaging Operation Specifications |
Zinc-plated products should not be stacked too high during inspection, as the coating may peel off or scratch. Handle them gently and pay attention to edge damage, corner defects, and surface scratches. |
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7 |
Other Projects |
Certificate of conformity, marking, packing method, and other related requirements. |
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11. Product Protection
11.1 Prevent Corner Damage
11.1.1 Handle the product gently during inspection to avoid edge damage.
11.1.2 Reasonable packing method should be selected for reworked products, and the occurrence of edge collision and corner shortage should be fully considered. The height of stacking or placement should be appropriate.
11.2 Rust and Corrosion Protection
11.2.1 During the inspection process, prevent the corrosion of the product surface by hand sweat.
11.3 Scratch Resistance
11.3.1 For large-sized products, the plates should be separated to prevent mutual friction and new scratches on the surface.
11.3.2 When inspecting products, products should not rub against each other to cause scratches.
11.4 Anti-Mixing
11.4.1 Each batch of products shall be clearly marked with batch No., code, brand name, specification, quantity, and other information.
11.4.2 Each box or barrel of products shall have the information on grade, specification, quantity, etc.
11.4.3 The separate circulation of products shall specify the separate reason.
12. Abnormal Quantity Processing Principles
When the quantity of products is abnormal, the first thing to do is to do a self-inspection. If there is still a discrepancy after re-verification, it should be reported to the responsible person for quantity confirmation. For small product weighing, it is allowed to have an upper and lower piece error per bag.
13. Disposal of Nonconforming Products and Feedback on Quality Anomalies
13.1 Nonconforming products or items requiring processing shall be immediately isolated and properly labeled with details including part No., specifications, quantity, and nonconformity characteristics. For products needing rework or repair, the labels must be clearly marked and timely notified. All reprocessed items shall undergo re-inspection.
13.2 Principles for Handling Reprocessed and Repainted Products
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Redo Reason |
Cladding Material |
Redo Process |
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The Surface Is Defective and Needs Grinding (Scratches, Scratches, Corrosion, etc.) |
Nickel, epoxy, chromium, tin, gold |
Re-deposit →Re-polish (grinding) →Re-deposit |
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Zinc, phosphorus |
Regrinding →Replating |
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Machine Chamfer Rework |
Nickel, epoxy, chromium, tin, gold |
Re-deposit →Chamfer →Re-deposit |
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Zinc, phosphorus |
Edge →Re-dip |
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Supplementary Angle or Supplementary Angle Rework |
Nickel, epoxy, chromium, tin, gold |
Backfill →Fill corner →Backfill |
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Zinc, phosphorus |
Complementary →Re-deposit |
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Demagnetization |
Nickel, epoxy, chromium, tin, gold |
Deposition →Demagnetization →Repositioning |
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Zinc, phosphorus |
Demagnetize →Replating |
13.3 If an abnormal quality is found and exceeds the specified proportion, the responsible department or person shall be notified within 10 minutes, and the feedback shall be sent to the department supervisor within 30 minutes.
13.4 Defective products shall be released for shipment (refer to historical release records). Release records shall be kept properly, and the release shall be approved by the management agent. Products such as rework, repair, nonconforming products, and products to be determined shall be clearly marked with the cause or nonconforming characteristics.
